Lump ore products and methods of making the same

ABSTRACT

A method of forming lump ores is provided which includes the steps of admixing a finely divided metal containing ore with an oxide or hydroxide of an alkaline earth metal, and a small amount of sulfur together with sufficient moisture to permit formation of aggregates such as lumps, pellets or blocks, forming the mix into aggregates, reducing the moisture to below 10 percent, subjecting the aggregates to carbon dioxide atmosphere to convert a substantial part of the alkaline earth metal oxide or hydroxide to carbonate in situ, and recovering the aggregate ore product so formed.

United States Patent [191 Imperato, Jr.

1*Dec. 16, 1975 LUMP ORE PRODUCTS AND METHODS OF patent subsequent to Aug. 6, 1991, has been disclaimed.

[22] Filed: Apr. 24, 1974 [21] Appl. No.: 463,728

Related US. Application Data [63] Continuation-impart of Ser. No. 797,825, Feb. 10,

' 1969, Pat. N0. 3,827,876.

UNITED STATES PATENTS 894,799 7/1908 Ricketts 75/3 2,844,457 7/1958 Amberg 75/3 3,027,251 3/1962 Schaefer 3,205,063 9/1965 Franklin 3,215,520 11/1965 lmperato 3,503,734 3/1970 Bell 75/5 Primary ExaminerPeter D. Rosenberg Attorney, Agent, or FirmBuell, Blenko & Ziesenheim [57] ABSTRACT A method of forming lump ores is provided which includes the steps of admixing a finely divided metal containing ore with an oxide or hydroxide of an alkaline earth metal, and a small amount of sulfur together with sufficient moisture to permit formation of aggregates such as lumps, pellets or blocks, forming the mix into aggregates, reducing the moisture to below 10 percent, subjecting the aggregates to carbon dioxide atmosphere to convert a substantial part of the alkaline earth metal oxide or hydroxide to carbonate in situ, and recovering the aggregate ore product so formed.

3 Claims, 1 Drawing Figure U.S. Patent Dec. 16, 1975 i, Q 6 who F. 0 O m 0 nhmo F 0 O 0 b 220 0/ mhmmoo 0 0 w w 7 6 E $3-0m 22 Q 5 2 om 85 9. 6 h. m m

Su p r A iiofl, Percent To Dry Wgt. of Mix LUMP ORE PRODUCTS AND METHODS OF MAKING THE SAME This application is a continuation-in-part of my copercent; the sulfur is 0.005 to 0.5 percent and the balance water, but not to exceed 10 percent of the weight of the mixture at the time of carbonation. The alkaline earth oxide or hydroxide preferably may be calcium oxpending application Ser. No. 797,825 filed Feb. 10, 5 ide, magnesium oxide, mixtures of calcium and magnel969, now US. Pat. No. 3,827,876. sium oxide, e.g. dolomitic mono-hydrate, magnesium This invention relates to lump ore products and hydroxide, calcium hydroxide and the like. The ore methods of making the same and particularly to a high may be any of the fine particle ore concentrates, rollstrength lump ore made from metal containing fines. ing-mill scale, ground ores and the like.

The need for a high strength lump ore suitable for use In the foregoing general description of this invention, in metallurgical furnaces such as blast furnaces, open I have set out certain objects, advantages and purposes hearth furnaces and the like is well known. of this invention. Other objects, purposes and advan- Natural, high-grade ores have been in large measure tages will be apparent from a consideration of the fol used up over years of production; and the present lowing description and the drawing showing the influsources of ore are generally of low grade and must be ence of the addition of sulfur on the high temperature beneficiated. Such low-grade, beneficiated ores are strength of carbonate bonded pellets. generally finely divided materials unsuited for charging into metallurgical furnaces. These finely divided ores EXAMPLE I must be formed into lumps in some manner to make 92.5% by weight of Lac Jeannine Concentrate, made them suited for use. Many methods have been proup of 20% unground concentrates and 80% concenposed such as, for example, sintering, briquetting with trates ground to 80% below 325 mesh was mixed with organic binders such as sugar, molasses and the like, 7.5% by weight of dolomitic mono-hydrate. To this forming lump ores with carbon dioxide and the like. In mixture was added varying amounts of sulfur and about many of these cases, the product will not stand up 7.0% of water. The several mixtures were formed into under weather or handling, in others the expense is expellets having a size consisting of minus /8 inch to plus cessive and in most the product, even though strong inch. The moisture content within the pellets was when cold, rapidly loses strength and disintegrates at then reduced to 23% and the pellets were placed in an elevated temperatures. Of all existing methods, that of atmosphere of carbon dioxide gas until a substantial forming lumps with a carbonate bond has the fewest portion of the alkaline earth metal was formed into aldisadvantages. 3O kaline earth metal carbonates in situ. The pellets were The present invention is directed to an improvement cooled and their compression strength was measured. on the carbonate bond process and to a product which The pellets where then tumble tested (5 lbs/200 revs.) has improved strength at elevated temperatures. The and the percentage above 4 inch determined. Finally, product of the present invention has all of the properthe SBF strength index after rotapping 15 minutes was ties of carbonate bonded pellets or lumps disclosed in determined as described in my US. Pat. No. 3,382,063 my US. Pat. No. 2,996,372 and, in addition, has higher issued May 7, 1968. The pertinent data is set out in strength at high temperatures. This is a highly desirable Table I hereinbelow and graphed on the attached drawcharacteristic, particularly for pellets to be used as a ing.

TABLE I SBF Strength Index After 15 Minutes Added Compression Tumble Test, 5 lbs./ Rotapping, 20 M Sulfur Strength, Avg., Lbs. 200 Revs. 1A" l600F. l900F.

None 159 65 84 0.009375 95 72 0.009375 154 96 72 85 0.01875 95 76 0.01875 182 96 77 86 0.0375 178 97 79 0.075 157 97 77 91 0.15 97 80 90 0.15 173 96 so portion of the charge for a blast furnace. The practice EXAMPLE n of this invention does not appear to significantly change the cold physical strength of pellets or lumps, but it does significantly increase the strength of the pellets or lumps at high temperatures.

In a preferred practice of my invention, l admix a finely divided ore with an oxide or hydroxide of an alkaline earth metal and finely divided sulfur, moisten and form the mixture into aggregates, such as lumps, reduce the moisture in the aggregates below 10 percent, and subject the formed lumps to an atmosphere of carbon dioxide until a substantial amount of the oxide or hydroxide of alkaline earth metal is converted to carbonate in situ. Preferably, the ore portion of the mixture is in the range of 60 to 95 percent of the mix ture; the alkaline earth oxide or hydroxide is 4.5 to 39.5

A series of tests using magnetite concentrate was made as follows:

92.5% by weight of magnetite concentrate was mixed with 7.5% by weight of dolomitic mono-hydrate. To this mixture was added about 10% by weight of water and the mixture was divided into two parts. To the second part an additional 0.15% sulfur was added and mixed. The two separate mixtures were formed into two groups of pellets having a diameter of about /2 inch. The moisture content was reduced to between 23% and the pellets placed in an atmosphere of carbon dioxide until a substantial part of the alkaline earth metal was converted to alkaline earth metal carbonate 1n situ.

The pellets were tested as described above and the results appear in Table ll TABLE II tion, however, it will be understood that this invention may be otherwise embodied within the scope of the fol- SBF Strength lndex After Minutes lowing claims.

TABLE III SBF Strength lndex After l5 minutes 7: Added Compression Tumble Test, 5 lbs./ Rotapping 7c M Sulfur Strength, Avg, Lbs. 200 Revs. 72 A" l600F.

None 181 98 79 O.l0 208 99 86 EXAMPLE III A series of tests using ground specular hematite con- I claim:

centrate originating from Labrador was made as follows:

91.0% by weight of specular hematite concentrate was mixed with 9.0% by weight of dolomitic monohydrate. To this mixture was added about 10% by weight of water and the mixture was divided into two parts. To the second part an additional 0.10% sulfur was added and mixed. The two separate mixtures were formed into two groups of pellets having a diameter of about /2 inch. The moisture content was reduced to between 2-3 percent'and the pellets placed in an atmosphere of carbon dioxide until a substantial part of the alkaline earth metal was converted to alkaline earth metal carbonate in situ.

The pellets were tested as described above and the results appear in Table III.

From the foregoing test data it will be noted that the addition of sulfur while having a slight improvement in tumble test, markedly improved the SBF strength index which is a measure of high temperature performance and is indicative of the ability of the pellet to satisfactorily withstand the temperatures and pressures of a blast furnace.

Coal or like fuel may be added as described in my US. Pat. No. 3,382,063 without detrimentally affecting the product.

In the foregoing specification l have described certain preferred practices and embodiments of my invenl. A low temperature method of making ore aggregates having high strength at elevated temperatures comprising the steps of:

a. admixing finely divided metal containing ore with one of the group consisting of oxides and hydroxides of an alkaline earth metal, between about 0.005 and 0.5 percent by weight of free sulfur and sufficient water to form the mass into aggregates;

b. forming the mixture into aggregates;

c. reducing the moisture level in the aggregates below 10 percent;

d. subjecting the formed aggregates to an atmosphere of carbon dioxide until a substantial portion of the alkaline earth metal is converted to alkaline earth carbonate in situ; and

e. removing the formed aggregates to the atmosphere for storage and use.

2. The method as claimed in claim 1 wherein the alkaline earth metal oxide and hydroxide is substantially all converted to carbonate.

3. A lump ore product consisting essentially of a finely divided metal containing ore, between about 0.005 to 0.5 percent by weight of free sulfur, less than 10 percent water and a bond of alkaline earth carbonate formed in situ by reacting carbon dioxide and one of the group consisting of alkaline earth oxides and hydroxides. 

1. A LOW TEMPERATURE METHOD OF MAKING ORE AGGREGATES HAVING HIGH STRENGTH AT ELEVATED TEMPERATURE COMPRISING THE STEPS OF: A ADMIXING FINELY DIVIDED METAL CONTAINING ORE WITH ONE OF THE GROUP CONSISTING OF OXIDES AND HYDROXIDES OF AN ALKLALINE EARTH METAL, BETWEEN ABOUT 0.005 AND 0.5 PERCENT BY WEIGHT OF FREE SULFUR AND SUFFICIENT WATER TO FORM THE MASS INTO AGGREGATES; B. FORMING THE MIXTURE INTO AGGREGATES; C. REDUCING THE MOISTURE LEVEL IN THE AGGREGATES BELOW 10 PERCENT; D. SUBJECTING THE FORMED AGGREGATES TO AN ATMOSPHERE OF CARBON DIOXIDE UNTIL A SUBSTANTIAL PORTION OF THE ALKALINE EARTH METAL IS CONVERTED TO ALKALINE EARTH CARBONATE IN SITU; AND E. REMOVING THE FORMED AGGREGATES TO THE ATMOSPHERE FOR STORAGE AND USE.
 2. The method as claimed in claim 1 wherein the alkaline earth metal oxide and hydroxide is substantially all converted to carbonate.
 3. A lump ore product consisting essentially of a finely divided metal containing ore, between about 0.005 to 0.5 percent by weight of free sulfur, less than 10 percent water and a bond of alkaline earth carbonate formed in situ by reacting carbon dioxide and one of the group consisting of alkaline earth oxides and hydroxides. 